Toe board rust hole repair how to cut a clean patch to weld for a seamless repair

Working on a 1968 Pontiac Firebird. We found some rust in the firewall toe board and needed replaced, this is a super common rust area on first gen f-body cars. Want to see how it can be done and maybe learn a thing or two? Then check out this part of the restoration of the "Great Pumpkin"
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[@stlbrian33]

Thank you. Your videos are always so helpful.

[@VinylVillageGarage]

Anytime! Glad to help

[@r3cursion254]

These videos are a treasure trove of information - thank you for taking the time to make them. I have a 68 bird, 76 TA, 77 TA, and 89 GTA. Because the hardcore bodywork scares me so much, I've gotten them from AZ, NV, NV, and NC. I know you make it all look much easier than it is, but I would almost consider saving a rusty bird at this point. How can I not at least tackle minitubs and a 4 link? Great work!!! Please keep saving the birds and taking us along for the ride!

[@VinylVillageGarage]

First off nice bird collection!!! Wow! I recently sold my 89 GTA awesome car but it’s good for me to let go of a couple gems I suppose, can’t keep them all or can I….????🤔 lol Mini tubs in one of my cars is on the list of hopes to do. I like taking on projects i have not attempted yet, in your case I say go for it and if you hit a roadblock I am certain we can find a Solution even if that means I get on a plane and help another fellow bird builder. Again sweet rides and thanks for doing your part in preserving and saving those birds!

[@perrywe1]

Awesome video as usual Jon. I am relatively new to your channel. I just completed my first 69 Camaro and have another waiting. Wish i had found your channel before but tuned in now. Thanks for all you do to share your expertise.

[@VinylVillageGarage]

Cool thanks for finding us. Glad to help, kinda like you said wish I had a resource like KZbin back when i started. With that said someone has to put it on there too. Been having fun playing cars for years now equally enjoying sharing the experience now. Good luck on your second Camaro

[@twobeards6714]

Hey Jon, I going to borrow my son's welder and cut up a Tahoe for practice. I guy just can't beat a Michigan salt bath body for rust...... The roof video with Brian was great. I love the fact that you haven't done a roof before. Cheers my friend and thanks again for the orange Dew. The old dog here up north keeps getting exposed to new things. That's what it's all about. I've never welded.

[@VinylVillageGarage]

Going to Arizona was really fun and more fun to mess with Brian. I figured never having done a roof panel before wasn’t too scary idea to do the first one 2,000 miles from home. It added to the challenge if anything. Hopefully your welding repairs aren’t for a panel that was as rusty as that roof panel. Good luck on your project, we are finishing up our last day at Firebird Fest today. Then we will be Eastbound and down,

[@twobeards6714]

Safe landing Bird Man. I'm sure it will be great to see mom and the girls. Thanks again for the Sunday morning Car toons.

[@VinylVillageGarage]

Very welcome my friend and I will keep your Sunday mornings fun

[@IMtheNOIR28]

Thanks so much for the great content! I’ve watched most if not all of your videos, and rewatched some. I’ve redone 13 Camaros from 76 on up, but I’m doing my first 68 Camaro (finally… an all numbers matching rust bucket… but a diamond in the ruff for me!). I wanted to thank you though, because your videos are so helpful! You make an otherwise intimidating task, doable. I appreciate ya!

[@VinylVillageGarage]

Right on!! What a cool project to bring back. I like buying them rough and the aftermarket support is great for these first gen cars and the quality of parts has greatly improved from 20 years ago. Good luck on your build! Thank you for watching

[@IMtheNOIR28]

@@VinylVillageGarage thanks! I’m gonna need it! I’ve honestly never had to replace any Panels or floors… till now! It’s always been simple body work, but I’m gonna be referencing your videos the whole way on this one! So thanks again! :)

[@VinylVillageGarage]

@@IMtheNOIR28 anytime!

[@davidbisnette7673]

Oops forgot to clarify, steering column and upper and lower dash needs to be removed for the floor to go down in place , that’s why it fits through the windshield opening but won’t go down in place . So it goes in and back out but not down in place, don’t lack much but won’t go.

[@VinylVillageGarage]

I tried and could not get the floor pan thru the windshield opening and down into place it just was like 2-3” too long. Now if you are saying the steel dash was removed from the car I could see It going in.

[@davidbisnette7673]

@@VinylVillageGarage yes within a couple inches but won’t go unless the dash has been removed, then it would drop right in, but hey I had to try it, live and learn

[@Sothrnbluz]

Great job as usual Jon, i always enjoy watchin your videos.

[@VinylVillageGarage]

Thanks! I appreciate you riding along on this KZbin journey it’s been really fun.

[@whitneymckim9651]

Excellent video- thank you so much for everything!

[@VinylVillageGarage]

Anytime!

[@davidbisnette7673]

Yes a full floor will go in through the windshield opening and it will comeback out , I’ve done it , great info on the toe boards that’s right where I’m at now , thanks for your great info on these birds

[@VinylVillageGarage]

Welcome glad this sounds like it might help.

[@davidbisnette7673]

@@VinylVillageGarage it has already answered several questions many thanks , I’ve got mine split in have “meaning subframe out “ and body all leveled up and will be cutting the remaining floor out , so looks like toe boards go in before the floor pan Thanks so much for these videos!

[@VinylVillageGarage]

I really enjoy hearing progress Updates, I love knowing another bird is getting closer to being back on the road. That’s the goal save as many as Possible

[@erockhefleyjr6852]

Good job J!👊🏻🤘🏻🔥

[@VinylVillageGarage]

Thanks buddy!!

[@938283]

Thanks!

[@VinylVillageGarage]

You bet!

[@IITopherII]

I love these videos! I’m just about to get started on my 68. I don’t have a clue what I’m doing, so I’m sucking up everything in these videos.

[@VinylVillageGarage]

That’s awesome good luck to you and Your project. you are the exact reason I have been posting these videos. Wanted give some insight on where to start and what to do. I didn’t have KZbin as a resource when I started wish I did. Anything I can help with let me know.

[@IITopherII]

@@VinylVillageGarage is there a better way to chat with you?

[@VinylVillageGarage]

Yup a few ways actually. Email link in the visor description is best or on Facebook and I still would deeply appreciate you leaving some likes and comments on KZbin on the occasion too. I have learned it really helps the growth of the channel hoping to reach as many people as we can

[@IITopherII]

@@VinylVillageGarage Awesome, thank you! I’ll definitely keep commenting and liking. These have given me a little hope;) Thanks again!!

[@dakotasclassiccars7246]

Great work! That came out awesome!

[@VinylVillageGarage]

Thank you sir, hoping someone finds this helpful for their project.

[@wmorri003]

Had to rewatch this one as it looks like I'm going to have to do the same thing to the 69. Now to decide whether or not to do the full floor pan or not :P

[@VinylVillageGarage]

Lol. I know a guy that is Willing to help.

[@shaggyscarshop]

Great Video!! Very informative. The new toe board looks great.

[@VinylVillageGarage]

Thank you! Much appreciated. When you get your car road worthy bring it to Firebird fest it is in St.Louis. Every year of Firebird is represented in various stages of completion. Your car would fit right in. I am actually here for this years show right now as we speak. would be awesome to you and your bird Here.

[@shaggyscarshop]

@@VinylVillageGarage Sounds good. Hopefully ill be getting it off to a body shop in the next month or so and then putting everything back together lol.

[@VinylVillageGarage]

@@shaggyscarshop that’s awesome you have done a lot to your car getting some paint on it will be great milestone.

[@fretsman68]

Very helpful, Jon, thanks again for the great welding tips and needed information!

[@VinylVillageGarage]

Welcome! heading home today from Firebird Fest we will be eastbound and down! It wound be amazing if you could make it here next year, it’s a very neat event the best part has been the people, this Firebird community is full of so many friends I didn’t know I had so to speak, everyone has been a blast to visit with. Especially this lady named Renea WOW! She loves these cars and Community and made this event even better.

[@burntclutches]

Great video Jon, love the welding tips

[@VinylVillageGarage]

Glad to help. Thanks for keeping motivated to keep PLUGging away. 😉

[@firstgenerationgarage2803]

Great job like always my brother little by little she will get done

[@VinylVillageGarage]

Thanks. Slow and steady wins the race. Hoping to have the floor installed this week when I get home from Firebird Fest in StLouis

[@firstgenerationgarage2803]

@@VinylVillageGarage cool have fun and please make a video

[@twobeards6714]

@@firstgenerationgarage2803 Hi Louis . I'm subbing to your channel today. I'm really impressed with the information that all of you gearheads share with us novices. I also love the fact that you support one another. I've got a 389 that's close to running on the stand. I can't wait to say " bring the thunder" and have the old girl come back to life. "Gotta save them birds" Old Ponchos are American classics. Long may they run.

[@VinylVillageGarage]

Thanks and well said

[@thomasls1vellmutcherson742]

Hey man love your content,I. Putting a 67 camaro convertible together and man if you had a video of installing rear tourqe boxes that would be so helpful

[@VinylVillageGarage]

Awesome thanks!! I don’t have a video yet, but definitely putting it on the list. Are you replacing the frame rails or under the rear seat floor pan also? Or just the torque box? Just wondering which way you are going to get it out.

[@thomasls1vellmutcherson742]

@@VinylVillageGarage If I can get away with it I was just going to replace the tourqe boxes

[@VinylVillageGarage]

If I was going to replace them keep in mind that they are sandwiched between the Frame rail and floor board I would prefer not to cut up the frame rail so I would most likely peal back the floor board for replacing them and not touch the frame

[@TheRad454]

Jon, can you tell us what thickness and wire type you use for your plug welds? Great job on the how to videos. Will be very helpful as I restore my 69.

[@VinylVillageGarage]

Yup the wire size I use for just about everything thing is 0.030 for some people that’s to big. I make it work because it’s what i leaned to do. But if you look up sheet metal for these cars/18-19 gauge .023 wire is more common. Basically do some test words and see which works best for you.